Fully recyclable shippers and methods of manufacture thereof

ABSTRACT

Fully recyclable shippers and methods of making fully recyclable shippers. The shippers are formed from polyethylene terephthalate and may include additional insulating filler material. The shippers are non-hygroscopic and, when filled with insulating filler material, have improved thermal insulating properties than other ecofriendly shippers while remaining completely recyclable by typical material reclamation facilities.

CROSS-REFERENCE TO RELATED APPLICATIONS

This disclosure claims priority to and the benefit of U.S. provisional application No. 63/157,336, filed Mar. 5, 2021, which is hereby incorporated by reference herein in its entirety.

FIELD OF THE DISCLOSURE

This disclosure relates generally to shippers and methods of making shippers and, in particular, relates to fully recyclable shippers and methods of making fully recyclable shippers.

BACKGROUND

Insulated shippers are typically used for shipping thermally-sensitive articles, such as perishable food, frozen desserts, nutraceuticals, or medicine. With the rising popularity of home meal kits, the use of insulated shippers used to preserve those meal kits has grown significantly.

So-called “ecofriendly” thermal insulation has traditionally been formed from a hybrid of paper and starch. However, these paper/starch systems are typically discarded by material recovery facilities (MRFs), and are therefore not always recycled. Other “green” materials like cotton and denim batts provide thermal insulation, but are very hygroscopic. Excessive absorption of moisture can have significant impacts on the thermal conductivity of the material, reducing these materials' effectiveness as insulation.

Furthermore, existing ecofriendly insulated shippers are often in the form of non-woven pads that cannot support a label or printed symbols. Since MRFs often rely upon printed labels/symbols to determine whether a particular article is processable by that MRF, the inability to print labels or symbols on an insulated shipper can impede recycling of the shipper.

Accordingly, improved shippers are needed, as well as methods for manufacturing them, for overcoming one or more of the technical challenges described above.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description is set forth with reference to the accompanying drawings. The use of the same reference numerals may indicate similar to identical items. Various embodiments may utilize elements and/or components other than those illustrated in the drawings, and some elements and/or components may not be present in various embodiments. Elements and/or components in the figures are not necessarily drawn to scale. Throughout this disclosure, depending on the context, singular and plural terminology may be used interchangeably.

FIG. 1 is a perspective view of one embodiment of a fully recyclable insulated shipper in an unassembled form, according to the present disclosure.

FIG. 2 is a perspective view of another embodiment of a fully recyclable insulated shipper in an unassembled form, according to the present disclosure.

FIGS. 3A-3C illustrate schematic views of one embodiment of mechanical locking features according to the present disclosure.

FIGS. 4A-4C illustrate schematic views of another embodiment of mechanical locking features according to the present disclosure.

FIG. 5 illustrates one embodiment of a thermal rivet according to the present disclosure.

FIG. 6 illustrates one embodiment of a thermally shaped snap according to the present disclosure.

FIGS. 7A-7B illustrate one embodiment of a thermoformed snap according to the present disclosure.

FIGS. 8A-8B are perspective views of one embodiment of corrugation according to the present disclosure.

FIG. 9 is a perspective view of another embodiment of corrugation according to the present disclosure.

FIG. 10 illustrates one embodiment of a heat-sealing process for forming insulated shippers.

FIGS. 11A-11B illustrate one embodiment of a three-panel system according to the present disclosure.

FIG. 12 illustrates one embodiment of a three-panel system according to the present disclosure.

FIG. 13 illustrates one embodiment of an insulated shipper according to the present disclosure.

FIGS. 14A-14B illustrate one embodiment of a shipper according to the present disclosure.

FIGS. 15A-15B illustrate embodiments of a three-panel system according to the present disclosure.

FIG. 16 illustrates one embodiment of an insulated shipper according to the present disclosure.

FIG. 17 illustrates one embodiment of corresponding three-panel systems according to the present disclosure.

FIGS. 18A-18B illustrate one embodiment of a shipper according to the present disclosure.

FIG. 19 illustrates one embodiment of an insulated shipper having a thermoformed handle according to the present disclosure.

FIG. 20 illustrates one embodiment of an insulated shipper having a thermoformed handle according to the present disclosure.

FIG. 21 illustrates one embodiment of an insulated shipper having a thermoformed handle according to the present disclosure.

DETAILED DESCRIPTION

Shippers and methods of making shippers are provided herein including shippers and methods of making shippers that are fully recyclable, non-hygroscopic, and, when the shipper is insulated, have improved resistance to thermal energy transfer compared to conventional “green” shippers. In particular, it has been discovered that shippers produced from polyethylene terephthalate (PET), including any insulated filling, staples, and fasteners, can satisfy most or all of the desirable characteristics of a conventional insulated shipper, e.g., in terms of resistance to thermal transfer and insulating against impacts, yet are readily recyclable by conventional material recovery facilities (MRFs). Furthermore, in preferred embodiments, these shippers are formed from panels that are rigid, preventing warping at the interfacing edges, improving the resistance to thermal energy transfer and permitting use of the shipper without the need for any corrugated cardboard. Further still, in embodiments in which the shipper is insulated, the panels have cavities that are sealed and prevent the ingress or egress of air. Finally, these shippers have surfaces able to support the attachment of a label or the printing, stamping, or embossing of symbols suitable for use by an MRF for identifying the shipper as recyclable.

Throughout this disclosure, various aspects are presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the disclosure. Accordingly, the description of a range should be considered to have specifically disclosed all the possible sub-ranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed sub-ranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6, etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.

As used herein, the term “about” with reference to dimensions refers to the dimension plus or minus 10%.

Fully Recyclable Shippers

Fully recyclable shippers are disclosed herein. In preferred embodiments, the shippers comprise at least polyethylene terephthalate (PET). By forming the shippers out of PET, the shipper is recyclable by conventional MRFs. In some embodiments, the shipper comprises a plurality of panels that comprise PET. In some embodiments, the shipper consists solely of PET or another recyclable material. In other embodiments, the shipper includes insulating material that is easily separable from the PET, such as beads formed from expandable PET or expandable polylactic acid.

The plurality of panels optionally may include one or more PET layers that define one or more cavities, which may be sealed so as to prevent ingress or egress of air or other contents. For example, a first PET layer may be thermoformed to have one or more open cavities, and a second PET layer may be configured to seal the one or more open cavities to form one or more sealed cavities. In some particular preferred embodiments, the one or more PET layers are rigid such that the insulated shipper does not readily deform, which thereby imparts resistance to thermal energy transfer at the interfacing edges of the panels. In some embodiments, the second PET layer that seals the one or more open cavities may also be a rigid PET layer, which may or may not be thermoformed, or it may be a flexible PET film.

As used herein, a “shipper” refers broadly to containers capable for being used to ship commodities and/or any item. Such containers may not be limited to use as a shipper and may be used as a tote, such as for carrying groceries or other belongings by a consumer; as an insulated cooler, such as for carrying or storing hot or cold contents; or another use. In some embodiments, the shipper is insulated. The decision to use the term “shipper” or “insulated shipper” is solely in the interest of brevity and is not intended to limit the applications for which the structures described herein may be used.

As used herein, “recyclable” refers to the ability for a material to be processed by a material recovery facility.

As used herein, a “cavity” refers to a space devoid of solid material. A cavity may include air, or it may approximate a vacuum.

As used herein, “thermoformed” refers to a manufacturing process by which a plastic blank, such as a PET blank or sheet, is pressed into a shaped mold in the presence of heat so that the plastic blank takes on the shape of the shaped mold. The plastic blank may be “pressed” into the mold using a vacuum, otherwise known as vacuum forming. PET sheets having thicknesses of between about 10 mil to about 40 mil have been shown to have favorable thermoforming properties. In some embodiments, the shipper includes mechanical locking features configured to attach a first PET layer to a second PET layer. The first PET layer and the second PET layer may be configured to form a single panel when attached together by the mechanical locking features. The first PET layer may be associated with a first panel and the second PET layer may be associated with a second panel, and the mechanical locking features therefore may be configured to attach the first panel to the second panel.

In some embodiments, the mechanical locking features include one or more shaped tabs in a first PET surface, each shaped tab configured to penetrate a slot in a second PET surface. A pair of shaped tabs, arranged proximal to one another but facing in opposite directions, may be configured to secure the first PET surface to the second PET surface by virtue of one shaped tab preventing lateral movement of the first PET surface in a first direction relative to the second PET surface, and the other shaped tab preventing lateral movement of the first PET surface in a second direction opposite to the first direction relative to the second PET surface, thereby securing the surfaces together. The shaped tabs may have any suitable shape, including a crescent-shaped tab such as the one illustrated in FIGS. 3A-3C; an arrow-shaped tab such as the one illustrated in FIGS. 4A-4C; or a trapezoid-shaped tab, such as the one illustrated in FIG. 17.

In other embodiments, the mechanical locking features include one or more snaps in a first PET surface, each snap configured to penetrate a corresponding snap in a second PET surface. The snaps may be formed by thermally shaping the PET surfaces, such as through the use of a heated horn that is pressed into stacked PET surfaces and rotated to displace the surfaces laterally, creating an overlapping portion that forms the snaps. The snaps may be formed simultaneously with thermoforming the PET surface. In some embodiments, the precise shape of the snaps may be tuned to create a tighter or more secure joint that requires a greater force to separate. FIGS. 7A-7B illustrate an example of corresponding snaps configured to join adjacent PET surfaces together.

In other embodiments, the mechanical locking features include one or more thermal rivets joining a first PET surface to a second PET surface. The thermal rivets may be formed by piercing stacked PET surfaces with a heated pin that melts the PET surfaces together, forming the thermal rivet. FIG. 5 illustrates an exemplary thermal rivet formation in two layered PET surfaces.

In some embodiments, the PET layers are secured together using one mechanical locking feature, two mechanical locking features, three mechanical locking features, or more mechanical locking features. A first PET layer may be secured to a second PET layer through the use of multiple mechanical locking features that are all of the same type (i.e., multiple crescent-shaped tabs), or more than one type of mechanical locking features may be utilized (i.e., crescent-shaped tabs and arrow-shaped tabs used to join a first PET layer to a second PET layer, or shaped tabs and snaps to join a first PET layer to a second PET layer). Any suitable combination of mechanical locking features may be selected for joining the PET layers and forming the shipper as described herein.

In some embodiments, the plurality of panels includes PET corrugation. As used herein, “corrugation” refers to the formation of three-dimensional structures out of an approximately two-dimensional material. In other words, a PET “sheet” is approximately two-dimensional because it has a high length:height ratio and high width:height ratio, but a PET sheet may be formed into a three-dimensional structure to form “corrugation.” Corrugated PET may be formed by folding a PET sheet, optionally in the presence of heat. Corrugated PET may be formed by extruding PET through a due having the shape of the desired corrugation. Any suitable method of forming corrugation may be used to form the PET corrugation as described herein.

In some embodiments, at least one of the plurality of panels includes thermoformed pocket walls and a thermoformed pocket back. The thermoformed pocket wall may form one or more open cavities. The thermoformed pocket back may be configured to attach to the thermoformed pocket walls to seal the one or more open cavities to form one or more sealed cavities, optionally in the presence of heat to isolate the cavity so as to prevent the ingress or egress of air or other contents.

In other embodiments, at least one of the plurality of panels includes one or more PET layers that are heat-sealed together to form a heat-sealed boundary. The one or more PET layers and the heat-sealed boundary may define one or more cavities. As used herein, “heat-sealing” refers to a manufacturing process by which PET layers are placed on top of one another and compressed between a heated platen and a base plate. The heated platen is configured to have a raised ridge having a shape corresponding to the desired shape of the heat-sealed boundary and the desired shape of the one or more cavities.

In other embodiments, at least one of the plurality of panels includes a PET envelope formed from PET film. In some embodiments, at least one of the plurality of panels includes a PET envelope having a rigid side (i.e., having a PET sheet) and a flexible side (i.e., having PET film).

In some embodiments, one or more panels in the shipper are thermoformed. In some embodiments, one or more panels include one or more PET layers that are heat-sealed together. In some embodiments, one or more panels include a PET envelope formed from PET film. The shipper may include panels that are thermoformed, panels that are heat-sealed, and/or panels that are formed at least partially from PET film. Any suitable combination of panels may be used to form the shipper as described herein.

In some embodiments, at least two of the plurality of panels share a continuous, common surface configured to fold along a region between the at least two panels. The at least two panels sharing the continuous, common surface may be formed in the same thermoforming process in a mold shaped to produce the at least two panels. The at least two panels may therefore be configured to fold against one another to form an “edge” between the panels that is free of gaps by virtue of the continuous, common surface. The at least two panels may further be configured to have mechanical locking features to secure the panels in a folded configuration.

In some embodiments, two or more of the plurality of panels share a continuous, common surface. In some embodiments, one or more of the plurality of panels are connected to one or more other panels using mechanical locking features. The shipper may include panels that share a continuous, common surface that are joined to other panels using mechanical locking features. Any combination of means to connect the panels may be used to form the shipper as described herein.

In some embodiments, the plurality of panels are characterized as having a right frustum shape. A “right frustum” is a shape resembling a right pyramid (a four-sided pyramid having a rectangular base) with the top truncated at a surface parallel to the base. In other words, the right frustum resemble a box having four tapered sides. In some embodiments, at least two panels share a continuous, common surface and, when these panels have a right frustum shape, folding the at least two panels together creates a seal between a tapered surface of a first panel and a tapered surface of a second panel.

In some embodiments, three panels share a continuous common surface such that, when the panels are folded together, a “C”-shaped structure is formed. Joining two of these “C”-shaped structures together may form a six-sided box suitable for use as a shipper. The three panels, prior to folding, may lay flat and may be stacked and nested with other three panel structures, resulting in significant reductions in the amount of space needed for shipping and storing unconstructed boxes.

In some embodiments, the plurality of panels are characterized as having a rectangular prism shape with four side surfaces and a top surface. In some embodiments, at least two panels share a continuous, common surface and, when these panels have a rectangular prism shape, folding the at least two panels together creates a seal between a side surface of a first panel and a top surface of a second panel.

In some embodiments, at least one of the plurality of panels includes one or more fasteners configured to maintain a shape of the panel. The fastener may be a PET-based thread or stitching passing through the panel, thereby joining a first PET layer to a second PET layer to prevent the PET layers from separating from each other by an amount greater than the length of the thread. In other words, the fastener may be configured to prevent the PET layers from “bowing outwards” due to physical pressure or a filling. The fastener may be a PET-based post positioned within the panel, thereby preventing a first PET layer from collapsing towards a second PET layer. Any suitable fastener configured to maintain the desired shape of the panel may be used to form the shipper as described herein.

In some embodiments, the shipper is an insulated shipper and includes an insulating filler disposed within the one or more cavities in the plurality of panels. The insulating filler may be a loose fill material, a shaped and formed material, or a combination thereof. The insulating filler may be recyclable, and may be formed from PET. The insulating filler may be staple fiber, optionally produced form waste fibers, having a size of from 1 denier to 15 denier per filament. The insulating fiber may be crimped and/or aerated to provide loft, which loft may be enhanced by finishes and/or water-soluble coatings. The insulating filler may include shaped PET filaments having cross-sections other than circular, such as trilobal or another shape. The insulating filler may include a misted adhesive, optionally water-soluble, that allows the insulating filler to take on a desired shape in agglomerate. The insulating filler may be formed into shaped, insulating pieces through a carding and combing process in which fibers are mechanically laid in alternating directions before linked or joined using an adhesive. The insulating filler may be an expanded foam bead, such as an expanded polylactic acid bead, expanded polyethylene terephthalate bead, expanded starch, or the like. In some embodiments, the insulating filler is recyclable and may be recycled along with the insulated shipper. In other embodiments, the insulating filler is not recyclable, but is capable of being easily separated from the insulated shipper by an MRF or as part of a subsequent recycling step.

In some embodiments, the insulated shipper includes a shaped insulating filler configured to maintain a desired shape. In some embodiments, the insulated shipper includes panels having fasteners configured to maintain a desired shape after charging the one or more cavities in the panel with insulating filler. In some embodiments, the insulated shipper includes one or more panels having fasteners, and one or more panels having shaped insulation. In some embodiments, a panel may have shaped insulation and fasteners. Any suitable combination of insulating filler and fasteners may be used to maintain a desired shape of the panels in the insulated shipper as described herein.

In some embodiments, the plurality of panels includes 5 or 6 panels that form a box. For example, two or more panels may share a continuous, common surface and may be configured to fold to form two or more sides of a box. The panels may be separated and configured to be joined together by mechanical locking features to form two or more sides of a box. In some embodiments, the plurality of panels includes 5 panels and the shipper further includes a PET lid panel attached to or attachable to the box to form a closed box.

In some embodiments, the shipper is non-hygroscopic. As used herein, “non-hygroscopic” refers to a structure or material that does not interact with or absorb moisture from the surrounding air. In other words, a structure that is non-hygroscopic retains its shape, density, weight, resistance to thermal energy transfer, and impact resistance properties regardless of the humidity of the surrounding air. In some embodiments, the shipper and any insulating filler is non-hydroscopic. In other embodiments, the non-hydroscopic insulated shipper is formed from panels having sealed cavities, and a hydroscopic insulating filler is charged within the sealed cavities. By forming the insulated shipper out of non-hydroscopic material and forming sealed cavities, the contents of the sealed cavities may be any suitable material, even hydroscopic, because the sealed cavities protect the contents of the cavity from moisture.

In some embodiments, the entire shipper is formed from PET, including any structural materials that form the plurality of panels, any insulating filler in the one or more cavities in the plurality of panels, any fasteners, any mechanical locking features, and the like.

FIG. 1 illustrates one embodiment of an insulated shipper 100 according to the present disclosure. Insulated shipper 100 includes five panels 102 having thermoformed pocket walls 104, a thermoformed pocket back 106, and a lid panel 108.

FIG. 2 illustrates one embodiment of an insulated shipper 200 according to the present disclosure. Insulated shipper 200 includes six panels 202 that are thermoformed and have a continuous, common surface 204. Insulated shipper 200 further includes mechanical locking features 206 configured to secure panels 202 together upon folding.

FIGS. 3A-3C illustrate one embodiment of mechanical locking features 300 according to the present disclosure. A first PET layer 302 has crescent-shaped tabs 304 configured to penetrate slots 306 in a second PET layer 308. FIG. 3A depicts the mechanical locking features when the crescent-shaped tabs and corresponding slots are formed. FIG. 3B depicts the crescent-shaped tabs and corresponding slots physically deformed to facilitate insertion of the crescent-shaped tabs into the slots. FIG. 3C depicts the first PET layer joined with the second PET layer by inserting the crescent-shaped tabs into the slots.

FIGS. 4A-4C illustrate one embodiment of mechanical locking features 400 according to the present disclosure. A first PET layer 402 has an arrow-shaped tab 404 configured to penetrate a slot 406 in a second PET layer 408. FIG. 4A depicts the mechanical locking features when the arrow-shaped tab and corresponding slot are formed. FIG. 4B depicts the arrow-shaped tab and corresponding slot physically deformed to facilitate insertion of the arrow-shaped tab into the slot. FIG. 4C depicts the first PET layer joined with the second PET layer by inserting the arrow-shaped tab into the slot.

FIG. 5 illustrates one embodiment of a thermal rivet 500 formed between a first PET layer 502 and a second PET layer 504. Heated pin 506 is pressed downward through the PET layers to form the thermal rivet 500.

FIG. 6 illustrates one embodiment of a thermally shaped snap 600 formed between a first PET layer 602 and a second PET layer 604. Heated horn 606 is pressed downward into the PET layers and rotated to shape the snap 600.

FIGS. 7A-7B illustrate one embodiment of a thermoformed first snap 702 formed within a first PET layer, and a thermoformed second snap 704 formed within a second PET layer. First snap 702 and second snap 704 have corresponding shapes such that first snap 702 and second snap 704 securely join together, thereby joining the first PET layer with the second PET layer. In some embodiments when the PET layer is part of a right frustum-shaped PET panel, the first snap and second snap may have a shape such as that illustrated in FIGS. 7A-7B, where the snaps have a rectilinear profile raised/lowered into a tapered surface. In other embodiments when the PET layer is part of a rectangular prism-shaped PET panel, the first snap and second snap may have a similar shape as that illustrated in FIGS. 7A-7B, but raise/lowered into a rectilinear surface.

FIG. 8A-8B illustrate one embodiment of a panel 800 having corrugation. PET layer 802 is shaped in order to have a three-dimensional structure. The PET layers are positioned together to form panel 800. In this embodiment, insulating filling 804 is charged into the spaces formed between the PET layers 802.

FIG. 9 illustrates one embodiment of a panel 900 having corrugation. In this embodiment, PET is extruded through a die having a cross-section 902.

FIG. 10 illustrates one embodiment of a heat-sealing process for forming a cavity 1000 in a PET panel 1002. PET layers 1004 and 1006 are positioned against one another and a platen 1008 having a heated ridge 1010 is lowered onto the PET layers to form heat-sealed boundary 1012 and the cavity 1000. Cavity 1000 may be charged with insulating filling prior to heat-sealing, resulting in a heat-sealed cavity with insulating filling.

FIG. 11A illustrates one embodiment of a three-panel structure 1100 having three panels 1102 connected by a continuous, common surface 1104. Each panel has a right frustum shape and snaps 1106, 1108 configured to interlock upon folding the three-panel structure 1100. FIG. 11B illustrates four three-panel structures 1100 stacked and nested on top of one another, demonstrating the potential of significantly reducing shipping and storage space requirements for the insulated shippers of the present disclosure. These stacked structures may subsequently be loaded with insulated filler and sealed with a second PET layer, as described herein. Alternatively, the stacked structures may be folded and utilized as components of a structure without the addition of insulated filler and a second PET layer.

FIG. 12 illustrates the three-panel structure 1100 of FIG. 11A after folding into a “C”-shaped structure. FIG. 13 illustrates a box 1300 formed from combining two three-panel structures 1100. In this embodiment, a second PET layer is affixed to the panels to produce a smooth outer surface and to seal the cavity formed in the PET panels.

FIGS. 14A and 14B illustrate another embodiment of a box 1400 with panels that omit a second PET layer. The cavity in the panels is therefore open and not sealed and would be suitable for use as, for example, a shipper without the need for corrugate. This embodiment has advantageous structural stability with dramatically reduced storage and shipping requirements due to the ability to stack and nest the three-panel structures.

FIGS. 15A and 15B illustrate embodiments of a three panel structure 1500, 1504 with panels 1502 having a rectangular prism shape. Three panel structures 1500 and 1504 differ in the shape of the PET boundary surrounding the panels 1502. The shape of the PET boundary affects how the three panel structure is joined to other PET panels and/or other three panel structures to form boxes, and can be tuned depending on the application and desired box geometry/properties. FIG. 16 illustrates a box 1600 formed from two three panel structures 1500.

FIG. 17 illustrates two three panel structures 1702 and 1704, each formed from panels having a rectangular prism shape. In order to facilitate folding into a box shape, each of structures 1702 and 1704 has panels of alternating size. When structures 1702 and 1704 are folded into “C”-shaped structures, the alternating size facilitates combining structures 1702 and 1704. FIGS. 18A and 18B illustrate a box 1800 formed from combining structures 1702 and 1704.

FIG. 19 illustrates an insulated structure 1900 having a handle 1902 thermoformed into one of the PET panels, with the handle extending into the cavity of the PET panel. FIG. 20 illustrates an insulated structure 2000 having a handle 2002 thermoformed into one of the PET panels, with the handle protruding from the surface of the PET panel. FIG. 21 illustrates an insulated structure 2100 having a handle 2102 extending from one side of the structure 2100 to the other, creating a “basket”-style handle. Insulated structure 2100 is depicted as having additional PET straps 2104 surrounding the PET panels as additional structural support.

The embodiments of the shippers and structures depicted in FIGS. 11A-20 vary in their shape and the inclusion or omission of insulated filler and a second PET layer on the panels. The shippers described herein may have a right frustum shape, a rectangular prism shape, or another suitable shape, and the shipper may be formed from panels having an open cavity, a sealed cavity, or a sealed cavity with insulated filler charged within. The shipper may be formed of some panels having insulating filler, and other panels without insulating filler. The decision to describe and depict only those combinations of these features in the figures is solely in the interest of brevity.

Methods of Making Fully Recyclable Shippers

Methods of making fully recyclable shippers are also described herein. In some embodiments, the method includes forming a plurality of panels from PET. In some embodiments, the method includes assembling the shipper from the plurality of panels.

In some embodiments, forming the plurality of panels includes thermoforming and the method includes providing a thermoforming machine. In some embodiment, forming the plurality of panels further comprises attaching a PET film to the thermoformed panels.

In some embodiments, at least one panel in the plurality of panels includes a cavity. In some embodiments, the method further includes attaching a second PET layer to the cavity of the at least one panel in the plurality of panels to seal the cavity. In some embodiments, the method includes inserting insulating filler into the cavity to form an insulated shipper.

EXAMPLES

The invention may be further understood with reference to the following non-limiting examples.

Example 1: Formation of Insulated Structure

An insulated structure was formed as described herein. A 24 mil PET sheet was purchased in roll-form. The PET sheet was thermoformed to produce a three panel structure. Each panel had a right frustum shape with a base area of 14″×14″. After thermoforming, the edges of the three panel structure were trimmed. Non-woven fiber insulation was placed in the cavity of the panels. Mylar® 850 PET film, available commercially from DuPont Teijin Films US, Chesterfield County, Va., USA was used to seal the outside of the cavity in the panels, securing the fiber insulation inside.

Example 2: Comparison of “Ecofriendly” Insulated Shippers

Presented below in Table A are thermal resistance, thickness, and mass of five different insulated shippers, including the PET-based shipper of the present invention. The PET shell was formed from 30 mil PET, and the second PET film used to seal the cavities was Mylar® 850 having a thickness of 150 gauge.

TABLE A Thermal Resistance of “Ecofriendly” Insulated Shippers Total Thermal Thermal Specimen Resistance Specimen Resistance/in mass pre-test Specimen Description (hr · F · ft²/Btu) Thickness (in) (hr · F · ft²/Btu · in) (lb/144 in²) Paper-lined starch peanuts 4.50 1.35 3.4 0.256 Starch-formed panel 3.40 1.00 3.4 0.143 Recycled denim 4.60 1.20 3.9 0.269 Paper-lined paper batting 3.70 1.06 3.5 0..355 1.5 dpf PET staple fill (1500 4.50 1.03 4.4 0.490 gsm) inside PET shell (Inventive) 1.5 dpf PET staple fill (650 4.20 1.03 4.1 0.317 gsm) inside PET shell

In a comparison of the thermal resistance of the wall of the insulated structure, the fine PET mesh of the inventive insulating structure performed better than comparable structures formed from other materials. In a comparison of the thermal resistance of the entire insulated structure, the difference increases significantly because the PET shell panels have edges that seal and provide superior performance.

Example 3: Infrared Analysis of Insulated Shippers

Each of the insulated structures described in Example 2 were placed in corrugate boxes. 5 pounds of dry ice was added to each box and allowed to fall a distance of 12 inches onto a concrete floor. The boxes were allowed to rest in a room with a temperature of 72° F. and 50% relative humidity for 1 hour. All corrugate boxes except for the box containing the insulated structure of the present disclosure showed frozen condensate at anywhere from 2 to 4 corners of the box, indicating thermal leak at the edges and corners. In contrast, the box containing the insulated structure of the present disclosure did not show frozen condensate on the outside of the box. The boxes were analyzed using FLIR infrared camera. All “Ecofriendly” shippers exhibited a corner which was at −20° C. or lower whereas the insulated shipper of the present invention showed a minimum temperature of 3° C. at the corner, demonstrating significant improvement in thermal energy retention.

While the disclosure has been described with reference to a number of embodiments, it will be understood by those skilled in the art that the disclosure is not limited to such embodiments. Rather, the disclosure can be modified to incorporate any number of variations, alterations, substitutions, or equivalent arrangements not described herein, but which are commensurate with the spirt and scope of the disclosure. Conditional language used herein, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, generally is intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements or functional capabilities. Additionally, while various embodiments of the disclosure have been described, it is to be understood that aspects of the disclosure may include only some of the described embodiments. Accordingly, the disclosure it not to be seen as limited by the foregoing described, but is only limited by the scope of the appended claims. 

That which is claimed is:
 1. A shipper, comprising: a plurality of panels comprising polyethylene terephthalate (PET), wherein the insulated shipper consists of recyclable material.
 2. The shipper of claim 1, wherein at least one of the plurality of panels comprises one or more PET layers defining one or more cavities.
 3. The shipper of claim 1, wherein at least two of the plurality of panels comprise mechanical locking features configured to join the two panels.
 4. The shipper of claim 3, wherein the mechanical locking features comprise one or more shaped tabs in a first PET surface, each shaped tab configured to penetrate a slot in a second PET surface.
 5. The shipper of claim 3, wherein the mechanical locking features comprise one or more snaps in a first PET surface, each snap configured to penetrate a corresponding snap in a second PET surface, wherein each snap is formed by thermoforming the PET layer.
 6. The shipper according to claim 1, wherein the at least one of the plurality of panels comprises PET corrugation.
 7. The shipper of claim 1, wherein at least one of the plurality of panels comprises a PET envelope formed from PET film.
 8. The shipper of claim 1, wherein at least two of the plurality of panels share a continuous, common surface configured to fold along a region between the at least two panels.
 9. The shipper of claim 8, wherein each of the at least two panels are characterized as having a right frustum shape with four tapered surfaces such that folding the at least two panels creates a seal between a tapered surface of a first panel and a tapered surface of a second panel.
 10. The shipper of claim 8, wherein each of the at least two panels are characterized as having a rectangular prism shape having four side surfaces and a top surface, such that folding the at least two panels creates a seal between a side surface of a first panel and a top surface of a second panel.
 11. The shipper of claim 1, wherein the plurality of panels comprise 5 or 6 panels forming a box.
 12. The shipper of claim 1, wherein the plurality of panels are translucent.
 13. The shipper of claim 1, wherein at least two of the plurality of panels interface at edges, wherein the interfacing edges form a seal configured to reduce thermal energy transfer between the at least two panels.
 14. The shipper of claim 1, wherein the insulated shipper is non-hygroscopic.
 15. The shipper of claim 1, wherein the entire shipper is constructed of PET.
 16. The shipper of claim 1, further comprising one or more handles for carrying the insulated shipper.
 17. The shipper of claim 2, wherein at least one of the plurality of panels comprises a thermoformed PET layer defining one or more open cavities, and a second PET layer configured to seal the one or more open cavities to form one or more sealed cavities.
 18. The shipper of claim 17, wherein the second PET layer is (i) a thermoformed PET layer, or (ii) a flexible PET film.
 19. The insulated shipper of claim 17, wherein the thermoformed PET layer and the second PET layer are heat-sealed together to form a heat-sealed boundary, such that the thermoformed PET layer, the second PET layer, and the heat sealed boundary define the one or more cavities.
 20. The insulated shipper of claim 17, further comprising an insulating filler disposed within the one or more cavities.
 21. A method of forming a shipper, comprising: forming a plurality of panels, and assembling the insulated shipper from the plurality of panels, wherein the plurality of panels are formed from polyethylene terephthalate (PET), and wherein the shipper consists of recyclable material.
 22. The method of claim 21, wherein forming the plurality of panels comprises thermoforming a PET sheet.
 23. The method of claim 22, wherein forming the plurality of panels further comprises attaching a PET film to the thermoformed panels.
 24. The method of claim 21, wherein at least one panel in the plurality of panels comprises a cavity, and wherein the method further comprises attaching a second PET layer to the at least one panel in the plurality of panels to seal the cavity.
 25. The method of claim 24, further comprising inserting insulating filler into the cavity in the at least one panel in the plurality of panels. 